This document describes the modeling and fabrication of an abrasive jet machine (AJM). It discusses: 1) The individual components of the AJM were modeled using CATIA software, including the mixing chamber, nozzle, and machining chamber. 2) The individual parts were then fabricated in the workshop as per the models. 3) The complete AJM was assembled, allowing for X-Y movement of the nozzle to machine complex shapes in difficult to machine materials like ceramics.

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Modelling and fabrication of Abrasive Jet Machine
Adarsh Singh1, F. Ujjainwala2, Ramanuj Kumar3
1Research Scholar, Industrial & Production Engineering Department, Shri G.S. Institute of Technology & Science,
23 Park Road, Indore, M.P., India
2Assistant Professor, Industrial & Production Engineering Department, Shri G.S. Institute of Technology & Science,
23 Park Road, Indore, M.P, India.
3Assistant Professor, School of Mechanical Engineering, KIIT University, Bhubaneswar, Odisha, India
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Abstract - With the development of technology, more and
more challenging problems faced by the scientists and
technologists in the field of manufacturing. The many new
materials and alloys that have been developed forspecificuses
possess a very low machinability. Producing complicated
geometries in such materials becomes extremely difficultwith
the usual methods. To tackle such difficult jobs two
approaches are possible, viz., (i) a modification of the
traditional processes and (ii) the development of new
processes. This paper presents the modelling of Abrasive Jet
Machine. The individual parts are fabricated andassembledin
the workshop.
Key Words: AJM, Modelling, Fabrication, Catia,
Assembly, Small Scale Industry.
1. INTRODUCTION
Abrasive Jet machining is nontraditional manufacturing
process that can make complex shapes on the surface of the
hard and brittle material. It is a process of material removal
through the action of a focused stream of fluid with abrasive
particles. It is especially used for machining super alloys,
ceramics, glass and refractory materials. Here, the material
removals are mainly due to the impingement of the fine
abrasive particles on the work surface. The metal cutting
occurs due to erosion caused by the abrasive particles
impacting the work surface at a high speed. As a result of
repeated impact, small bits of material get loosened and
separated from the workpiece surface, exposing a fresh
surface to the jet. The AJM is different from conventional
sand blasting as the latter is a surface cleaning process and
AJM is a metal cutting process. The process is used mainlyto
cut complex shapes in hard and brittle materials which are
heat sensitive and have a tendency to chip easily. AJM is also
used for removing burrsand cleaning operations.AJMisfree
from and vibration and chatter problems. As the carrier gas
itself serves as a coolant, the cutting action is cool [1].
1.1 Concept of AJM
A schematic layout of AJM is shown in Figure 1.1In AJMairis
compressed in an air compressor at a pressure 5 bar, which
is used as carrier gas. Gases, like CO2, N2, etc., which may be
directly issued from a cylinder can also be used as carrier
gas. The carrier gas first passes through a pressureregulator
to obtain the required working pressure. The gas is then
passed through an air filter regulator to remove anyresidual
water vapour. To remove any oil vapour or particulate
contaminant the same is passed through a series of filters.
After that carrier gas enters a closed chamber known as the
mixing chamber. The abrasive particles enter the chamber
from a hopper through a metallic sieve. The sieve is
constantly vibrated by an electromagnetic shaker. The mass
flow rate of abrasive (16 gm/min) entering the chamber
depends on the frequency and amplitude of vibration of the
sieve. The abrasive particles are then carried by the carrier
gas to the machining chamber via an electromagnetic on-off
valve. The machining chamber is essential to contain the
machined particles and abrasives in a safe and eco-friendly
manner. The machining is carried out at high velocity (200-
300 m/s) abrasive particles are issued from the nozzle onto
a work surface traversing under the jet.
Fig -1: Schematic Layout of AJM
The components are: -
1. Air compressor
2. Air filter
3. Dehumidifier
4. Pressure gauge
5. Mixing chamber
6. Pressure regulator
7. Nozzle
8. Machining chamber
9. Vibrator
10. Work holding device

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1.2 Advantages of AJM
 It is able to cut brittle, fragile or glass and heat sensitive
material without damage.
 It is able to cut intricate shape or complex profileinhard
or brittle materials.
 As the machining action is cool, so in this process, no
heat is generated.
 No tool change required.
 High-quality surface finish.
 The surface of the work piece is cleaned automatically.
 Capital cost is low.
1.3 Disadvantages of AJM
 Very low material removal rate. Hence theapplicationof
AJM is limited.
 The process produces a taper cut always.
 In certain substances, abrasive particles might settle
over the work piece.
 Nozzle life is less.
 It can’t be used machining soft materials.
 It can’t be used to drill blind holes.
1.4 Applications of AJM
 Used in cutting slots, thin sections, contouring, drilling.
 It can be also used for etching and deburring process.
 It is sometimes used for cleaning and polishingofTeflon
and plastics components.
 It is used for paint removal.
 It is used mainly in textile and leather industries.
 It is used in nuclear plant dismantling.
2. Literature review
R. Balasubramaniam et al. [2] investigated the abrasivejet
deburring process parameters and the edge quality of
Abrasive Jet deburred components. Experimental design
based on Taguchi Orthogonal array was used to
systematically measure the influence of the major cutting
parameters on abrasive jet deburred specimens. The
experimental specimens used were 1.5mm thick, 25mm
square grade AISI304 stainless-steel sheets. Burrs were
generated by the face milling operations. ANOVA method
was used for the visual inspection of edge quality. It was
found that the deburring process is significantly affected by
‘height of the jet’ and ‘impingement angle’. It was concluded
that Abrasive Jet deburring process advantageous than
manual deburring process. The quality of deburred
component mainly increases by the generation of edge
radius.
Y. Yamauchi et al. [3] investigated the effect of work piece
properties on machinability in abrasive jet machining of
ceramic materials. Three kinds of common abrasives viz.
Aluminium Oxide, Silicon Carbide, and synthetic diamond
were employed for conducting the experiment. The target
materialsused were four kindsof ceramicsviz. ZrO2, Si3N4,
Al2O3, SiC. A laser scanning microscope was used to
measure the volume that was removed by abrasive jet
machining. The machinability of the AJM process was
compared with the established models of solid particle
erosion, in which the material removal is assumed to
originate in the ideal crack formation system. Further,itwas
found that the AJM test results did not dependontheerosion
models, because the relative hardness oftheabrasiveagainst
the target material, which has not taken into account in the
models, is critical in the machining process. It was also
concluded that AJM process had high potential micro-
machining method as damage free for many materials
because the radial cracks did not extend downwards by the
impact of the particle during the machining process.
S. Ally et al. [4] used surface evolved models to predict
Abrasive jet machining of metallic substrates. The abrasive
jet inclination angle of erosion rate was measured. The
material is Aluminum 6061-T6,Ti-6Al-4VTitaniumalloyand
316L stainless steel. The jet inclination angle was measured
using 50 micrometersAl2O3 abrasivepowderlaunchedatan
average velocity of 110m/s. The peak erosionratewasfound
to occur 200 to 350 relative to the surface for all three
systems. It was found that Aluminum has a high volumetric
erosion rate than Titanium alloy which is higher than the
stainless steel erosion rate on a volumetric basis, which in
turn is significantly lower than a brittle material such as
glass and polymers. It was also found that where a high
degree of control etches is desired; AJM of metals is best
suited for etching of relatively shallow features. It was
concluded that scanning electron micrograph and EDX
analysis of the eroded surface of 316L stainless give a
significant amount of particle adhering with a lessamountin
the Titanium alloy.
N. S. Pawar et al. [5] investigated abrasive materialseasand
in vibrating chamber. The tungsten carbide nozzle wasused
in the abrasive jet micro machining process. The sand of
100-150 micron was used for the experiment. The work
piece used was a glass of thickness 4 mm. The evaluated
performances were material removal rate and flow rate. It
was found that the impact through nozzle caused severe
erosion on the material work piece. Itwasdemonstratedthat
the erosion of material surface depended on velocity,
direction and brittleness of the material. The experiment
was performed by using the combination of two different
parameters viz. Standoff distance and pressure. From the
result, it was concluded that material removal rate and flow
rate were similar to actually abrasive used like aluminum
oxide, silicon carbide, etc. It was noticed that by increasing
feed rate width of the cut was also increased. It was also
found that at greater stand–off distance and feed rate, taper
cut was found to be a higher slot.

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Rajkamal Shukla and Dinesh Singh [6] used Taguchi
method for experimental investigation of abrasive water jet
machining parameters. The material used is AA6351
aluminum alloy. Parameterssuch astransverse speed,stand
off distance and mass flow rate are considered to obtain the
influence of these parameters on kerf top width and taper
angle. Regression models have been developed to correlate
the data generated using experimental results. The
percentage contribution of standoff distance in kerf top
width and taper angle is found to be 77.642% and 81.774%
respectively.
A. Ghobeityet al. [7] predicted modelsof abrasive jetmicro
machining for masked and unmasked borosilicate glass
channels by using 25 micro meter aluminum oxide. A novel
technique is used for the velocity distributionoftheparticles
in the jet of an abrasive jet micro machining. It was found
that the velocity decreased linearly from the centre line of
the jet to the periphery, Weibull distribution followedbythe
probability of a particle arriving at the surface a given radial
distance from the centre of the impacting jet. To predict the
cross sectional profile of unmasked channels this Weibull
distribution was used with an extension of the already
existing model. Time-dependent particle mass flux and
velocity distribution were used for modeling of the effect of
the nozzle. Further, it was demonstrated that the
distribution of net erosive power over the cross section
passing through the round nozzle had the same form as the
distribution along the diameter of the stationary nozzle. By
measuring the particle velocity across the cross section of
the jet, it was found that the velocity decreased linearlyfrom
the centre to the periphery. It was concluded that by
reducing the incident particle energy flux caused by mask
edge scattering the prediction of masked channel profiles is
affected.
Manabu Wakuda et al. [8] investigated the material
response of alumina ceramics to the abrasiveparticleimpact
in the AJM process. Three types of abrasive grains, viz.
Aluminum Oxide, Silicon Carbide and Synthetic diamond
were used for the impact on alumina ceramics. AJM
equipment with Micro-Blaster (MB2-ML-001, Sintobrator,
Japan) was used which is capable of shooting fine abrasives
along with a pressurized nitrogen gas stream through a
small jet nozzle. It was found that the softest abrasive
aluminum Oxide leadsto roughening of the alumina surface,
but causes no mark, due to the lack of the hardness of the
abrasive against that of the work piece. It wasalsofoundthat
by employing Silicon Carbide, a relatively smooth face could
be produced as a result of ductile behaviour under the
elevated temperature caused by the abrasiveimpacts.Bythe
impingement of Synthetic Diamond abrasive, a large-scale
fragmentation was observed and therefore the surface
became rough.
Dong-Sam Park et al. [9] improved micro-machining using
the machining ceramics, semiconductors, electronic devices
and LCD. For micro grooving of glass, he checked the
performance of micro-AJM. Process parameters for micro-
AJM were pressure, velocity and time, stand-off distance,
material propertiesnumber of nozzle scanningtimes.Micro-
grooving consisted of masking process, abrasive jet
machining process and a mask removing and cleaning
process. White Alundum was used for machining whose
main ingredientswere Al2O3. The results showedthatwhen
the heat amount was 160mJ at 1050°C, then the masking
results were considerable and otherwise were poor. In the
same way, grooving results showed that when the heat
amount was150mJ the hole type wasnot wellgenerated,but
when the amount was 160mJ the machined grooves were in
generally in good condition.
3. Modelling of AJM
The whole 3D modelling was done in CATIA. Following
articlescover the modelling of different componentsof AJM.
3.1 Mixing Chamber
Fig -2: 3D Model of Mixing Chamber
3.2 Nozzle
Fig -3: 3D Model of Nozzle

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3.3 Assembly for X-Y Movement of Nozzle
Fig -4: 3D Model of Nozzle Stand Assembly
3.4 Machining Chamber
Fig -5: 3D Model of Machining Chamber
3.5 Complete Assembly
Fig -6: 3D model of AJM
4. Fabrication of AJM
The systems were developed as per modelling and then
assembled.
4.1 Mixing Chamber
The designing of the mixing chamber was done specially for
proper mixing of the compressed air and abrasives. For this
purpose, we used a seamless mild steel pipe and joined a
circular plate, both at top and bottom ends.Threeholeswere
drilled on the structure, the first at the top; the other two
were on the surface. The top hole was used to pass on the
abrasives into the chamber. From the two holes on the
surface, one was used to pass the compressed air from the
dehumidifier and the other brought out the mixture of
compressed air with abrasive to the nozzle.
Fig -7: Actual view of mixing chamber
4.2 Nozzle
The nozzle was used for the general purpose of increasing
the velocity of the mixture of compressed air and abrasives.
Owing to this purpose it was tapered in shape. The nozzle
was prepared from a cylindrical block which underwent
plain turning in the beginning. The nozzle was then tapered
for the required use. Inside tapering was done using
different drill bitsin continuation. The nozzle wasfabricated
using EDM. The material used was D-2 steel.
Fig -8: Actual view of nozzle

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4.3 Assembly for X-Y Movement of Nozzle
The nozzle was connected to a nut and bolt assembly. The
assembly consisted of two nuts one of which was fixedwhile
the other was moving. While rotating themovingnutby360°
the nozzle moved a distance of 1 pitch which equals to
1.5mm in the X direction.
In Y direction, the end of the nut was attached to a working
table which also consisted of a nut for the movement of the
nozzle. The purpose for moving the nozzle in Y directionwas
to make a slot in the work piece.
Fig -9: 3D Model of Complete Assembly
4.4 Machining Chamber
It was cubical in shape. It was basically made up of glass
structure. The entire structure was closed so as to prevent
the abrasives from spreading around. It housed the nozzle
assembly and the bench vice. The bench vice was used for
holding the work piece. The used abrasiveswereremovedby
opening the bottom glassof the working chamber.Oneofthe
side glass was closed in such a way that it can be removedby
removing the threaded bolt. It was done so to load and
unload the work- piece.
Fig -10: Actual view of machining chamber
4.5 Complete Assembly
After fabricating different components of abrasive jet
machining, a frame like structure was designed and
fabricated which supports all the major components of
abrasive jet machining. The figure shows the assembly
design of abrasive jet machining. All the above components,
including dehumidifier, carrier gassupply line and pressure
gauge were mounted on the frame, which gives the overall
experimental setup.
The material used for manufacturing the aboveframeismild
steel. The carrier gas supply pipe is made up of pneumatic
material which has high strength. The purpose of using
pneumatic material instead of general pipe was to prevent
the pipe from being eroded due to the flow of abrasive grit
under high pressure.
Fig -11: Actual view of AJM
5. Result and conclusion
In AJM, a focused jet or stream of abrasive particles carried
by high-pressure gas (carrier) is made to impinge on the
work surface through a nozzle. The metal cuttingoccursdue
to erosion caused by the abrasive particles impacting the
work surface at high speed. As a result of the impact, small
bits of materials get loosened and separated from the
workpiece surface, exposing a fresh surface to the jet. This
process is capable of cutting intricate holes and shapes in
materials of any hardness and brittleness.
Some of the remarks on the present work:
 Each part is modelled in CATIA software.
 Each part is fabricated in the workshop.
 Each part is assembled to make a complete AJM setup.

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6. Future Scope
 Manual nut assembly has been used to vary the nozzle
tip distance. This process can be done automatically.
 For shaking of the mixing chamber, wehaveusedhandle
manually. This can be done automatically by using a
motor.
REFERENCES
[1] Amitabha Ghosh and Asok Kumar Mallik,Manufacturing
Science, East-West Press, New Delhi, 1985.
[2] R. Balasubramaniam and J. Krishnan, “Investigation of
AJM for deburring”, Journal of Materials Processing
Technology, 2014, pp 52-58.
[3] S. Kanzaki and Y. Yamauchi,“Effect of work piece
properties on machinability in abrasive jet machiningof
ceramic materials”, Journal of the InternationalSocieties
for Precision Engineering and Nanotechnology,2012,pp
193-198
[4] S. Ally, J. K. Spelt and M. Papini,“Prediction of machined
surface evolution in the abrasive jet micro-machiningof
metals”, International Journal on the Science and
Technology of Friction Lubrication and Wear, 2012, pp
89-99.
[5] N. S. Pawar, R. R. Lakhe and R. L. Shrivasstava,“A
comparative experimental analysis of sea sand as an
abrasive material using silicon carbide and mild steel
nozzle in vibrating chamber of Abrasive Jet Machining
process”, International Journal of Scientific and
Research Publications, Vol. 3, Issue 10, 2013.
[6] Rajkamal Shukla, and Dinesh Singh,“Experimentation
investigation of abrasive water jet machining
parameters using Taguchi and Evolutionary
optimization techniques”, Swarm and Evolutionary
Computation, 2017, pp 167-183.
[7] A. Ghobeity and T. Krajac,“Surface evolution models in
abrasive jet micromachining”, International Journal on
the Science and Technology of Friction Lubrication and
Wear, 2014, pp 185-198.
[8] Manuba Wakuda and Yukihiko Yamauchi,“Material
Response to particle impact during abrasive jet
machining of alumina ceramics”, Journal of Materials
Processing Technology, 2013, pp 177-183.
[9] Dong-sam Park, Myeong-Woo Choo and Honghee Lee,
“Micro-grooving of glass using micro-abrasive jet
machining”, Journal of MaterialsProcessingTechnology,
2004, pp 234-240.